Motor Assembly

ABSTRACT

A motor assembly and method of operating the motor assembly include a motor, a memory to store calibrated parameters of the motor, and electronics coupled to the memory and the motor. The electronics are configured to retrieve the calibrated parameters from the memory, provide the calibrated parameters to an external system, and receive control signals for driving the motor from the external system. The control signals are based on the calibrated parameters. The calibrated parameters include a motor speed versus no-load current relationship for the motor determined by a procedure that includes performing an initial calibration of the motor, wearing in the motor after performing the initial calibration, performing a final calibration of the motor after wearing in the motor, and storing the calibrated parameters in the memory based on the initial calibration and the final calibration.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/154,087, filed Jan. 13, 2014, and claims priority to U.S. ProvisionalPatent Application No. 61/752,409, filed Jan. 14, 2013 and entitled“Motor Assembly.” Each of which is incorporated herein by reference inits entirety.

TECHNICAL FIELD

Embodiments of the present invention are directed to the management oftorque parameters in surgical instruments such as staplers or vesselsealers to control the force at the distal tip.

DISCUSSION OF RELATED ART

Minimally invasive surgical techniques are aimed at reducing the amountof extraneous tissue that is damaged during diagnostic or surgicalprocedures, thereby reducing patient recovery time, discomfort, anddeleterious side effects. As a consequence, the average length of ahospital stay for standard surgery may be shortened significantly usingminimally invasive surgical techniques. Also, patient recovery times,patient discomfort, surgical side effects, and time away from work mayalso be reduced with minimally invasive surgery.

A common form of minimally invasive surgery is endoscopy, and a commonform of endoscopy is laparoscopy, which is minimally invasive inspectionand surgery inside the abdominal cavity. In standard laparoscopicsurgery, a patient's abdomen is insufflated with gas, and cannulasleeves are passed through small (approximately one-half inch or less)incisions to provide entry ports for laparoscopic instruments.

Laparoscopic surgical instruments generally include an endoscope (e.g.,laparoscope) for viewing the surgical field and tools for working at thesurgical site. The working tools are typically similar to those used inconventional (open) surgery, except that the working end or end effectorof each tool is separated from its handle by an extension tube (alsoknown as, e.g., an instrument shaft or a main shaft). The end effectorcan include, for example, a clamp, grasper, scissor, stapler, vesselsealer, cautery tool, linear cutter, needle holder, or other instrument.

To perform surgical procedures, the surgeon passes working tools throughcannula sleeves to an internal surgical site and manipulates them fromoutside the abdomen. The surgeon views the procedure from a monitor thatdisplays an image of the surgical site taken from the endoscope. Similarendoscopic techniques are employed in, for example, arthroscopy,retroperitoneoscopy, pelviscopy, nephroscopy, cystoscopy, cisternoscopy,sinoscopy, hysteroscopy, urethroscopy, and the like.

Minimally invasive telesurgical robotic systems are being developed toincrease a surgeon's dexterity when working on an internal surgicalsite, as well as to allow a surgeon to operate on a patient from aremote location (outside the sterile field). In a telesurgery system,the surgeon is often provided with an image of the surgical site at acontrol console. While viewing a three dimensional image of the surgicalsite on a suitable viewer or display, the surgeon performs the surgicalprocedures on the patient by manipulating master input or controldevices of the control console. Each of the master input devicescontrols the motion of a servo-mechanically actuated/articulatedsurgical instrument. During the surgical procedure, the telesurgicalsystem can provide mechanical actuation and control of a variety ofsurgical instruments or tools having end effectors that perform variousfunctions for the surgeon, for example, holding or driving a needle,grasping a blood vessel, dissecting tissue, or the like, in response tomanipulation of the master input devices.

Manipulation and control of these end effectors is a particularlybeneficial aspect of robotic surgical systems. For this reason, it isdesirable to provide surgical tools that include mechanisms that providethree degrees of rotational movement of an end effector to mimic thenatural action of a surgeon's wrist. Such mechanisms should beappropriately sized for use in a minimally invasive procedure andrelatively simple in design to reduce possible points of failure. Inaddition, such mechanisms should provide an adequate range of motion toallow the end effector to be manipulated in a wide variety of positions.

Surgical clamping and cutting instruments (e.g., non-robotic linearclamping, stapling, and cutting devices, also known as surgicalstaplers; and electrosurgical vessel sealing devices) have been employedin many different surgical procedures. For example, a surgical staplercan be used to resect a cancerous or anomalous tissue from agastro-intestinal tract. Many known surgical clamping and cuttinginstruments, including known surgical staplers, have opposing jaws thatclamp tissue and an articulated knife to cut the clamped tissue betweenthe inserted staples.

The operation of a surgical stapler typically involves the transfer of arelatively high amount of force to the end effector of the surgicalstapler. One way of transferring force involves transferring rotarymotion from actuators to the end effector. Under-clamping by providingtoo little force to the end effector can result in less than a completeclamp, leaving a large tissue gap and resulting in inadequately formedstaples. Over-clamping by providing too much force to the end effectorscan result in increased deflection of the end effector and again resultin a large tissue gap, which may result in inadequately formed staples.

Similar considerations can be applied to vessel sealers. A vessel sealerclamps the tissue, seals two sides, and divides the tissue between theseals with a knife. Again, improper clamping can result in impropersealing of the tissue.

Therefore, there is a need to control the clamping of an instrument toprovide for proper clamping during operation.

SUMMARY

In accordance with some embodiments of the present invention acalibrated motor assembly is provided. A method of calibrating a motorin a motor assembly according to the present invention includesacquiring an assembled motor assembly; performing an initial calibrationof the motor in the motor assembly; wearing in the motor; performing afinal calibration of the motor; and storing calibration data in themotor assembly.

A motor assembly according to some embodiments of the invention caninclude at least one motor; a memory to store calibrated parametersrelated to the at least one motor; and electronics coupled to thememory, the at least one motor, the electronics including interfaces tocouple with a clamping device and a system to control the operation ofthe at least one motor. The calibrated parameters are determined for theat least one motor with a procedure that includes performing an initialcalibration of the at least one motor; wearing in the at least onemotor; performing a final calibration of the at least one motor; andstoring calibration data in the memory. In some embodiments, the atleast one motor includes a clamping motor. In some embodiments, the atleast one motor includes a firing motor. In some embodiments, lifetimeparameters are stored in the memory.

These and other embodiments are further discussed below with respect tothe following figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a minimally invasive robotic surgery systembeing used to perform a procedure.

FIG. 2 is a perspective view of a surgeon's control console for arobotic surgery system shown in FIG. 1.

FIG. 3 is a perspective view of a robotic surgery system electronicscart shown in FIG. 1.

FIG. 4 diagrammatically illustrates a robotic surgery system as shown inFIG. 1.

FIG. 5 illustrates a patient side cart of a surgical system as shown inFIG. 1.

FIGS. 6A and 6B illustrate a surgical stapler.

FIGS. 6C and 6D illustrate a vessel sealer.

FIG. 7 illustrates coupling of a surgical stapler as illustrated inFIGS. 6A and 6B with a motor assembly.

FIG. 8 illustrates operation of a surgical system utilizing a surgicalstapler.

FIG. 9A illustrates a method of calibrating a surgical stapler accordingto some embodiments of the present invention.

FIG. 9B illustrates a surgical stapler during calibration.

FIG. 9C shows example data obtained during a calibration procedure.

FIGS. 10A and 10B illustrate a procedure for calibrating a motorassembly according to some embodiments of the present invention.

FIGS. 10C and 10D illustrate calibration of a no-load current for motorsin a motor assembly according to some embodiments of the presentinvention.

FIGS. 10E and 10F illustrate calibration of a torque constant for motorsin a motor assembly according to some embodiments of the presentinvention.

FIG. 11 shows a method of adjusting torque limits for a surgical staplerduring operation.

In the figures, elements provided with the same element number have thesame or similar function.

DETAILED DESCRIPTION

In the following description, specific details are set forth describingsome embodiments of the present invention. It will be apparent, however,to one skilled in the art that some embodiments may be practiced withoutsome or all of these specific details. The specific embodimentsdisclosed herein are meant to be illustrative but not limiting. Oneskilled in the art may realize other elements that, although notspecifically described here, are within the scope and the spirit of thisdisclosure.

This description and the accompanying drawings that illustrate inventiveaspects and embodiments should not be taken as limiting—the claimsdefine the protected invention. Various mechanical, compositional,structural, and operational changes may be made without departing fromthe spirit and scope of this description and the claims. In someinstances, well-known structures and techniques have not been shown ordescribed in detail in order not to obscure the invention.

Additionally, the drawings are not to scale. Relative sizes ofcomponents are for illustrative purposes only and do not reflect theactual sizes that may occur in any actual embodiment of the invention.Like numbers in two or more figures represent the same or similarelements.

Further, this description's terminology is not intended to limit theinvention. For example, spatially relative terms—such as “beneath”,“below”, “lower”, “above”, “upper”, “proximal”, “distal”, and thelike—may be used to describe one element's or feature's relationship toanother element or feature as illustrated in the figures. Thesespatially relative terms are intended to encompass different positions(i.e., locations) and orientations (i.e., rotational placements) of adevice in use or operation in addition to the position and orientationshown in the figures. For example, if a device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be “above” or “over” the other elements or features.Thus, the exemplary term “below” can encompass both positions andorientations of above and below. A device may be otherwise oriented(rotated 90 degrees or at other orientations) and the spatially relativedescriptors used herein interpreted accordingly. Likewise, descriptionsof movement along and around various axes includes various specialdevice positions and orientations. In addition, the singular forms “a”,“an”, and “the” are intended to include the plural forms as well, unlessthe context indicates otherwise. And, the terms “comprises”,“comprising”, “includes”, and the like specify the presence of statedfeatures, steps, operations, elements, and/or components but do notpreclude the presence or addition of one or more other features, steps,operations, elements, components, and/or groups. Components described ascoupled may be electrically or mechanically directly coupled, or theymay be indirectly coupled via one or more intermediate components.

Elements and their associated aspects that are described in detail withreference to one embodiment may, whenever practical, be included inother embodiments in which they are not specifically shown or described.For example, if an element is described in detail with reference to oneembodiment and is not described with reference to a second embodiment,the element may nevertheless be claimed as included in the secondembodiment.

Minimally Invasive Robotic Surgery

FIG. 1 shows a plan view illustration of a Minimally Invasive RoboticSurgical (MIRS) system 10, typically used for performing a minimallyinvasive diagnostic or surgical procedure on a Patient 12 who is lyingon an Operating table 14. The system can include a Surgeon's Console 16for use by a Surgeon 18 during the procedure. One or more Assistants 20may also participate in the procedure. The MIRS system 10 can furtherinclude a Patient Side Cart 22 (surgical robot) and an Electronics Cart24. The Patient Side Cart 22 can manipulate at least one removablycoupled tool assembly 26 (hereinafter simply referred to as a “tool”)through a minimally invasive incision in the body of the Patient 12while the Surgeon 18 views the surgical site through the Console 16. Animage of the surgical site can be obtained by an endoscope 28, such as astereoscopic endoscope, which can be manipulated by the Patient SideCart 22 to orient the endoscope 28. The Electronics Cart 24 can be usedto process the images of the surgical site for subsequent display to theSurgeon 18 through the Surgeon's Console 16. The number of surgicaltools 26 used at one time will generally depend on the diagnostic orsurgical procedure and the space constraints within the operating roomamong other factors. If it is necessary to change one or more of thetools 26 being used during a procedure, an Assistant 20 may remove thetool 26 from the Patient Side Cart 22, and replace it with another tool26 from a tray 30 in the operating room.

FIG. 2 is a perspective view of the Surgeon's Console 16. The Surgeon'sConsole 16 includes a left eye display 32 and a right eye display 34 forpresenting the Surgeon 18 with a coordinated stereo view of the surgicalsite that enables depth perception. The Console 16 further includes oneor more input control devices 36, which in turn cause the Patient SideCart 22 (shown in FIG. 1) to manipulate one or more tools. The inputcontrol devices 36 can provide the same degrees of freedom as theirassociated tools 26 (shown in FIG. 1) to provide the Surgeon withtelepresence, or the perception that the input control devices 36 areintegral with the tools 26 so that the Surgeon has a strong sense ofdirectly controlling the tools 26. To this end, position, force, andtactile feedback sensors (not shown) may be employed to transmitposition, force, and tactile sensations from the tools 26 back to theSurgeon's hands through the input control devices 36.

The Surgeon's Console 16 is usually located in the same room as thepatient so that the Surgeon may directly monitor the procedure, bephysically present if necessary, and speak to an Assistant directlyrather than over the telephone or other communication medium. However,the Surgeon can be located in a different room, a completely differentbuilding, or other remote location from the Patient allowing for remotesurgical procedures.

FIG. 3 is a perspective view of the Electronics Cart 24. The ElectronicsCart 24 can be coupled with the endoscope 28 and can include a processorto process captured images for subsequent display, such as to a Surgeonon the Surgeon's Console, or on another suitable display located locallyand/or remotely. For example, where a stereoscopic endoscope is used,the Electronics Cart 24 can process the captured images to present theSurgeon with coordinated stereo images of the surgical site. Suchcoordination can include alignment between the opposing images and caninclude adjusting the stereo working distance of the stereoscopicendoscope. As another example, image processing can include the use ofpreviously determined camera calibration parameters to compensate forimaging errors of the image capture device, such as optical aberrations.

FIG. 4 diagrammatically illustrates a robotic surgery system 50 (such asMIRS system 10 of FIG. 1). As discussed above, a Surgeon's Console 52(such as Surgeon's Console 16 in FIG. 1) can be used by a Surgeon tocontrol a Patient Side Cart (Surgical Robot) 54 (such as Patent SideCart 22 in FIG. 1) during a minimally invasive procedure. The PatientSide Cart 54 can use an imaging device, such as a stereoscopicendoscope, to capture images of the procedure site and output thecaptured images to an Electronics Cart 56 (such as the Electronics Cart24 in FIG. 1). As discussed above, the Electronics Cart 56 can processthe captured images in a variety of ways prior to any subsequentdisplay. For example, the Electronics Cart 56 can overlay the capturedimages with a virtual control interface prior to displaying the combinedimages to the Surgeon via the Surgeon's Console 52. The Patient SideCart 54 can output the captured images for processing outside theElectronics Cart 56. For example, the Patient Side Cart 54 can outputthe captured images to a processor 58, which can be used to process thecaptured images. The images can also be processed by a combination ofthe Electronics Cart 56 and the processor 58, which can be coupledtogether to process the captured images jointly, sequentially, and/orcombinations thereof. One or more separate displays 60 can also becoupled with the processor 58 and/or the Electronics Cart 56 for localand/or remote display of images, such as images of the procedure site,or other related images.

FIG. 5 shows a Patient Side Cart 22. The Patient Side Cart 22 shownprovides for the manipulation of three surgical tools 26 and an imagingdevice 28, such as a stereoscopic endoscope used for the capture ofimages of the site of the procedure. Manipulation is provided by roboticmechanisms having a number of robotic joints. The imaging device 28 andthe surgical tools 26 can be positioned and manipulated throughincisions in the patient or through an orifice in the patient so that akinematic remote center is maintained at the incision to minimize thesize of the incision. Images of the surgical site can include images ofthe distal ends of the surgical tools 26 when they are positioned withinthe field-of-view of the imaging device 28.

FIGS. 1-5 illustrate a multi-port surgical robot. It should beunderstood that embodiments of the present invention can also beutilized with a single port surgical robot. In either multiport orsingle port surgeries, surgical tools 26 are passed through cannulasinserted into patient 12 at the surgical site. The surgical tools 26 aremanipulated through patient side cart 22 while the surgeon directs andviews the procedure from surgeon's console 16. Processor 58 andelectronics cart 24 can be utilized to translate inputs from the surgeonat the surgeon's console 16 to actual motion of end effectors ofsurgical tools 26. Surgical tools that may be typically utilized includeclamps, graspers, scissors, staplers, cautery tools, linear cutters,needle holders, and other instruments. Each of the surgical tools 26 isattached to, and driven by, patient side cart 22 under the direction ofsurgeon 18, as provided by processor 58 and electronics cart 56.Processor 58 and electronics cart 16 translate the inputs from surgeon18 into driving actions at patient side cart 22 that affect the motionsof the end effectors of surgical tools 26. In particular, surgical tools26 can include one of a stapler or vessel sealer according to thepresent invention.

Clamping Instrument

The surgical tools 26 that can be employed in surgical system 10 caninclude clamping instruments such as staplers and electronic vesselsealers. Such devices can be used to resect cancerous or anomaloustissue, for example from a gastro-intestinal tract. FIG. 6A illustratesan example of a stapler 600. Stapler 600 includes a stapler end effector602, a wrist 604, an instrument shaft 606 and a chassis 608.

As shown in FIG. 6A, stapler end effector 602 includes an anvil 610 anda jaw 612. A stapler cartridge 614 can be inserted onto jaw 612. In someembodiments of stapler 600, a cutting knife blade 616 is configured suchthat it can travel along the long direction of anvil 610. Stapler 600can be utilized as a grasper, however during operation as a stapler jaw612 is forced against anvil 610 to clamp tissue between jaw 612 andanvil 610.

A proper tissue gap, the distance between jaw 612 and anvil 610 duringclamping, is important for proper staple formation. If the tissue gap istoo large, the staples will not properly form during firing. A largetissue gap can be caused by clamping overly thick material between jaw612 and anvil 610. In some cases, stapler end effector 602 can be drivento a predetermined clamp position and the torque required to achievethis position measured. If the torque is too high, then anvil 610 hasdeflected and the tissue gap will be too big. In some embodiments, atorque limit can be set and end effector 602 can be moved toward apredetermined clamp position. If the torque limit prevents end effector602 from achieving the predetermined clamp, then an appropriate tissuegap cannot be achieved. In both cases, accurate sensing or control ofthe torque acting on anvil 610 is important for accurately detectinginadequate tissue gap

When the stapler is fired, staples are forced through the interveningtissue and into anvil 610 by sled 618 traveling along jaw 612. Thedistance between jaw 612 and anvil 610, which is the tissue gap,determines proper formation of the staples. Controlling the tissue gapcan help to ensure proper staple formation. Adequate clamping forcebetween jaw 612 and anvil 610 provides for an appropriate tissue gap forstaple formation. Adequate clamping force on the tissue can be afunction of cartridge 614, which determines the length of the staples.

Additionally, knife blade 616 (which may be formed as an I-Beam orattached to sled 618) is translated along anvil 610 to separate thestapled tissue. In some embodiments, sled 618 and knife blade 616 areformed within cartridge 614. If the tissue gap is incorrect, the staplesmay be improperly formed, causing tissue damage and other complications.In some embodiments, stapler 600 may be a linear stapler. Someembodiments may not include knife blade 616 and therefore performstapling without transection.

Achievement of hemostasis and pneumostasis (the sealing of tissue usinga stapling device) depends on providing appropriate pressure, whichresults from the clamping force, on the tissue after firing such thatthe staples adequately compress the tissue to prevent bleeding andleaks. Providing too much pressure may result in the staples squeezingthe tissue hard enough to cut off the blood supply entirely, preventingthe tissue from healing and leading to necrosis.

As discussed above, if too much clamping force is used to position endeffector 602 into a predetermined clamp position, then a deflectionbetween the tips of anvil 610 and jaw 612 may result in incorrectclamping. Additionally, too little clamping force and jaw 612 may notfully close against anvil 610 into a predetermined clamp position, againresulting in improper stapling of the tissue.

Stapler cartridge 614 can be color coded for particular circumstance,including tissue thickness. Although several different colors can beutilized, the following chart of color coding may apply:

Cartridge Open Staple Closed Staple Color Tissue Thickness Height (mm)Height (mm) Gray Mesentery/Thin 2.0 0.75 White Vascular/Thin 2.5 1.0Blue Regular 3.5 1.5 Gold Regular/Thick 3.8 1.8 Green Thick 4.1 2.0Black Very Thick 4.4 2.3

Cartridge 614 may come in various lengths, for example 30, 45, or 60 mm.A single stapler 600 can fire many reloads, with each cartridge beingfired once. Cartridge 614 may include data storage that holds, forexample, cartridge serial number, cartridge type, part number, style,direction of firing, length of firing, cartridge color, firing torque,maximum deflection and other data. In some embodiments, knife blade 616and sled 618 are part of cartridge 614 and are replaced with eachre-load.

FIG. 6B illustrates staple end effector 602 clamped to tissue 650. Asshown in FIG. 6B, cartridge 614 includes staples 652. During firing,sled 618 can travel along jaw 612 to drive staples 652 that are housedin cartridge 614 through the clamped tissue and into pockets 654 onanvil 610. Although FIG. 6B illustrates an embodiment where each leg ofstaple 652 can be formed into a portion of the “B”-shape by anindividual pocket 654, in some embodiments staple 652 can be shaped by asingle pocket 654. Pockets 654 are configured to form staples 652 into a“B”-shape, which provides optimal sealing. Knife 616 cuts the tissuebetween rows of staples to cut the stapled tissue. Cartridge 614 mayproduce a number of rows of staples, for example two (2) or three (3)rows on each side of the cut formed by knife 616 may be formed.

The clamping action of jaw 612 and anvil 610 and the firing motion ofsled 618 and knife 616 are driven by chassis 608 coupling a torque fromexternal motors (not shown in FIG. 6A) to couplers 660. Couplers 660 canbe, for example, drive shafts or cables. Couplers 660 travel along shaft606 and couple to cams, gears, screws, or worm drives in end effector602 and cartridge 614. Couplers 660 are also utilized to control wrist604. As shown in FIG. 6A, chassis 608 controls couplers 660 bycontrolling the tension of cables or rotation of drive shafts that runthrough instrument shaft 606 to end effector 602. Clamping of jaw 612against 610 can be managed with a cam mechanism that rotates jaw 612into anvil 610 or alternatively rotates anvil 610 into jaw 612. Thefiring of sled 618 and knife 616 can, for example, be driven by a leadscrew mechanism driven by a drive shaft coupler 660. In someembodiments, clamping of jaw 612 and anvil 610 and firing of sled 618and knife 616 can be controlled by rigid drive shafts while control of anormal grip of jaw 612 and anvil 610 as well as the pitch and yaw ofwrist 604 can be controlled by cables. In some embodiments, clamping andfiring may be controlled by cables.

In order to provide for proper clamping during firing of stapler 600, aparticular clamping force is provided between jaw 612 and anvil 610.That clamping force is initially provided by the torque of a motorcoupled to chassis 608. The appropriate torque to provide the clampingforce may vary from one stapler to another due to manufacturingvariances of chassis 608 and friction that may be present for example inshaft 606, wrist 604, and the mechanical operation of jaw 612 and anvil610. Furthermore, as stapler 600 wears, the appropriate clamping inputtorque may drift during the lifetime of stapler 600 and it may take lesstorque applied to chassis 608 to affect the proper clamping forcebetween jaw 612 and anvil 610. Since improper clamping force results inimproper tissue gap due to improper deflection of the jaw 612 and anvil610, if too much torque is applied to chassis 608 or there is improperclosing of the jaw 612 and anvil 610 through too little clamping force,then improper formations of staples 652 may occur during firing. Suchimproper clamping may also damage tissue 650, both as a result ofimproper staple formation and improper clamping during the process.

As discussed above, a common driving mechanism for clamping jaw 612against anvil 610 is with utilization of a cam mechanism. Appropriateclamping, however, cannot be determined solely by the position of thecam. This is a result of the flexibility of jaw 612 and anvil 610, whichcan result in additional separation of the tips of jaw 612 and anvil610. When too much clamping torque is applied, the tip separationbetween jaw 612 and anvil 610, the tissue gap, may be too high resultingin improper staple formation during firing. Therefore, in someembodiments of the present invention a torque limit is set and appliedto stapler 600 such that excessive tip separation (tissue gap) isprevented during clamping. Firing is only permitted if stapler 600 canreach the fully clamped position while the torque limit is implemented.If the torque limit prevents clamping (stalls), then the tissue cannotbe adequately compressed and if clamping were to proceed an excessivetip separation due to the flexibility of the jaw 612 and anvil 610 wouldresult. Stapler 600, therefore, can be considered to be clamped when jaw612 and anvil 610 have reached full travel (i.e. by achieving theexpected number of turns of a leadscrew or cardan) and the torque limithas not been reached.

Similar issues occur with a vessel sealer. FIG. 6C illustrates a vesselsealer 630. Vessel sealer 630 includes an end effector 632, wrist 634,an instrument shaft 636 and a chassis 638. End effector 632 includes ajaws 642 and 640, which are clamped onto tissue that is to be sealed.Instead of staples, vessel sealer 630 can utilize an RF method ofsealing the tissue clamped between jaws 640 and 642.

FIG. 6D illustrates end effector 632 with jaw 650, which can be eitherof jaws 640 or 642. As shown in FIG. 6D, jaw 650 includes an electrode654 embedded in jaw case 652. Knife 646 can be driven along a track 658formed in electrode 654. Jaw case 652 has tips 656 that extend beyondand above electrode 654 such that a minimum gap between electrodes 654is maintained during the process. In some embodiments, the minimum gapcan be, for example, 0.006 inches. When fired, jaws 640 and 642 can beenergized to seal the tissue and knife blade 646 can travel along track658 in jaws 640 and 642 to divide the tissue. Energy is supplied throughelectrodes 654 in jaws 640 and anvil 642. In some embodiments, knifeblade 646 can be activated separately from the sealing energy.

A proper clamping force is needed to provide for proper seal formationduring electrocautery. Excessive clamping force may damage the drivingmechanism, for example a leadscrew mechanism. Therefore, operation ofvessel sealer 630 depends on providing enough clamping force to jaws 640and 642 while not damaging vessel sealer 630 itself. The upper forcelimit is based on the goals of 1) not damaging vessel sealer 630 and 2)providing consistent performance.

This disclosure will focus on operation of stapler 600, although oneskilled in the art will recognize that other instruments such as vesselsealer 630 can also benefit. In either stapler 600 or vessel sealer 630,various motions of the end effector are controlled through the chassisby cables running through the instrument shaft. The chassis is driven inorder to affect the couplers in the instrument shaft, which in turncontrol motions at the end effector. As discussed above with respect tostapler 600, the couplers that control clamping and firing can be driveshafts, cables, push-pull rods, or other mechanism. The torque on motorsthat are utilized to drive the chassis translates to forces applied tovarious components of the end effector.

FIG. 7 illustrates surgical stapler 600 mounted on a motor assembly 702.Motor assembly 702 can be mounted to the stapler instrument, which isthen mounted to the surgical arms of the patient side cart 22. Motorassembly 702 can also be mounted to, or made part of, one of thesurgical arms of patient side cart 22. As shown in FIG. 7, motorassembly 702 includes one or more motors 710 that are mechanicallycoupled through a mechanical coupler 706 and electronics 712. Mechanicalcoupler 706 can be coupled to chassis 608 when stapler 600 is mounted tomotor assembly 702. In some embodiments, the one or more motors 710 mayinclude a clamping motor and a firing motor. The combination of one ormore motors 710 and electronics 712 of motor assembly 702 can bereferred to as a motor pack. Motors that drive wrist 604 may be includedin motor assembly 702 or may be separate from motor assembly 702.Mechanical coupler 706 transmits the torque from the one or more motors710 into chassis 608, where the torque is transmitted to cables 660 bymechanical converter 714.

Electronics 708 includes storage memory and interface electronics tostore and transmit data to motor assembly 702. The data stored inelectronics 708 include parameters relevant to surgical stapler 600.Such data can be utilized to identify and control stapler 600 and, forexample, may include the serial number, the instrument type, lifetime(i.e. the number of firings), and other information regarding stapler600. Storing instrument data in electronics 708 has been described, forexample, in U.S. Pat. No. 6,866,671, which is herein incorporated byreference in its entirety.

Electronics 708 can also communicate with data storage 716 on cartridge614 when cartridge 614 is positioned into end effector 602. Data storage716 can, for example, store data related to the cartridge, including itsidentification, cartridge lot number, cartridge type, cartridge serialnumber, cartridge firing status, cartridge color, length, torque offset,and other data. The data stored in data storage 716 of cartridge 614 canbe transmitted to a control system for determining how stapler 600,cartridge 614, and motor assembly 702 are to be utilized together.

Motor assembly 702 can include electronics 712 that exchange datathrough interface 704 with electronics 708, communicates that data andother information through patient side cart 54 to other components ofsystem 10, and receives data and instructions from other components ofsystem 10. Electronics 712 can also store data related to motor assembly702, for example the motor assembly type, serial number, lifetime (i.e.number of firings lifetime), and other information regarding theoperation of motor assembly 702. Electronics 712 may also provide inputto the one or more motors 710 that are mechanically coupled to stapler600 as well as receiving data from sensors monitoring the position ofthe motors or other components of the mechanism. Such input may be tocontrol and limit the current provided to the one or more motors 710 andmay including one or more current loop control circuits and/or positionloop control circuits.

FIG. 8 illustrates operation of a surgical system with stapler 600,although another clamping instrument such as a vessel sealer may beutilized. As shown in FIG. 8, electronics 708 of chassis 608 includes amemory 808 and electronics 806. Memory 808 includes non-volatile memorythat can store parameters regarding stapler 600. As discussed above,such parameters may include operating parameters of stapler 600,lifetime of stapler 600, type of stapler 600, and other parameters.Electronics 806 is also coupled to read data storage 716 from cartridge614 and relay those parameters. Electronics 806 can read parameters frommemory 808 and parameters from data storage 716 in response to signalsreceived through interface 704.

In some embodiments, interface 704 includes electrical connectionsbetween chassis 608 and motor assembly 702. Electronics 806 can includea processor and other electronics that read data from and write data tomemory 808.

Electronics 712 of motor assembly 702 includes electronics 810 andmemory 812. Electronics 810 can be a processor or other electronics thatinterfaces to electronics 806 through interface 704. As shown in FIG. 8,electronics 810 also provides control signals to the one or more motors710. FIG. 8 shows motors 802 and 804. Motors 802 and 804 drivemechanical converter 714 in order that the functions of stapler 602 areperformed.

In particular, motor 804 is a clamping motor and operates stapler 600 toprovide clamping between jaw 612 and anvil 610 against tissue 650. Motor802 is a firing motor and operates stapler 600 and cartridge 614 to firestapler 600. Stapler 600 is fired when the stapler 600 is clamped. Aclamped condition can be determined when the output position of motor804 reaches the appropriate clamp position while simultaneously a torquelimit is implemented to prevent excessive tip separation. The torqueprovided by motor 804 can be controlled by the current provided to motor804. The current provided to motor 804 can be controlled by electronics810. In operation, torque limits are provided for motor 804 based uponthe instrument and motor assembly (or motor pack) it is used with.Clamping can be determined when the appropriate position of motor 804 isreached while the appropriate torque limit is implemented. The torquelimit is directly related to a current limit for motor 804, andtherefore the torque limit is reached when the current draw of motor 804reaches a corresponding current limit.

Electronics 810 may include processors and electronics that executeinstructions stored in memory 812. As such, electronics 810 can includecurrent controllers and position controllers for controlling motors 804and 802, which can be the clamping motor 804 and firing motor 802,respectively. As is further shown in FIG. 8, electronics 810 can includevarious sensors 820 that monitor the performance of motor assembly 702.Sensors 820 can, for example, include temperature sensors to measure themotor assembly temperature, current sensors to measure the current drawnby each of the at least one motors 710, and position sensors to measurethe output position of each of the at least one motors 710.

Memory 812 may include a combination of volatile and non-volatile memoryand may store data and executable instructions for controlling the oneor more motors 710. Memory 812 can include parameters related to motorassembly 702, including serial number, part number, version number,configuration information (type, style, expiration information, currentcontroller gains, position controller gains, gear ratio), temperaturecoefficients, wear coefficients, friction coefficients, motor K_(T) (theparameter that relates torque to current) and other information.

Other functions of stapler 600, for example operation of wrist 604 andtranslation of sled 618 and knife 616 during firing, can be provided byother motors or combinations of motors operating with mechanicalconverter 714. As is understood, mechanical converter 714 can becombinations of gears and cams that are coupled to cables 660 to providethe appropriate motions. Current to other motors, such as firing motor802 or other driving motors, can also be controlled by electronics 810.

Electronics 810 is further coupled to receive instructions and providedata to system 800. System 800 can represent a combination of surgeon'sconsole 52, electronics cart 56, processor 58, and display 60 of system50 in FIG. 4. As such, system 800 includes one or more processors 802,memory 804, data storage 814, and a user interface 816. User interface816 can be surgeon's console 52, display 60, keyboards, touchscreens, orother suitable input devices. Storage 814 can be any data storage systemsuch as flash memory, a hard drive, CD reader or reader of other storagemedia, or other device for storing data. Memory 804 can include volatileand non-volatile memory for storage of data and processing steps. Insome cases, memory 804 can be loaded with data, including programmingsteps, from storage 814.

In some embodiments, electronics 810 and electronics 806 may supportinteger math. Algorithms operating on electronics 806 and 810 can bescaled appropriately to perform mathematical operations assigned to themwhile controlling motors 804 and 802.

In operation, parameters regarding the operation of stapler 600 are readfrom memory 808 and provided to electronics 810 and processor 802.Surgeon input is received at user interface 816. Processor 802 executesinstructions to translate the input to instructions for operation ofstapler 600 and provides instructions to electronics 810. In someembodiments, the parameters read from memory 808 can be utilized indetermining the instructions provided to electronics 810. Electronics810 provides signals to the one or more motors 710 to provide themotions indicated by processor 802. Those motions are then translated toend effector 602. The signals provided to the one or more motors 710 mayalso be predicated on parameters read from memory 808. In some cases,processor 802 may provide or rewrite parameters in memory 808 to beutilized during the next utilization of stapler 600.

In general, motor assembly (or motor packs), staplers, and cartridgesare not matched. During a procedure, any motor assembly can be utilizedwith any stapler and any of the various cartridges can be utilized inthe stapler. Therefore, data storage 716 holds parameters associatedwith the stapler cartridge 614, memory 808 stores parameters associatedwith that particular stapler 600, and memory 812 stores parametersassociated with that particular motor assembly 702.

Initialization of the Stapler

As discussed above, staple cartridges (also referred to as reloads) areavailable in a variety of sizes that are identified by color. Each colorcartridge corresponds to a particular staple leg length. Commoncartridges include green (4.3 mm leg length), blue (2.5 mm leg length),and white (1.5 mm leg length) cartridges 614. In order to properly formstaples, anvil 610 and jaw 612 need to be positioned within closeproximity to ensure that staples 652 hit pockets 654 in anvil 610 andform the desired “B” shape (FIG. 6B). Stapler 600 utilizes a“cantilever” style of clamping and, as discussed above, if the clampingtorque limit is too high it is possible to deflect the tip of anvil 610and jaws 612 away from each other to the point where staples 652 willnot properly form when staples 652 are pushed out of cartridge 614during the firing process. This situation may develop if there is toomuch tissue in the jaws during clamping with too much torque. To preventthis and ensure the proper tip gap is maintained, the clamping torque islimited.

Under ideal circumstances, if each of staplers 600 where identical, allstaplers 600 would use the same torque limits. However, manufacturingvariations and tolerances can result in significant variation betweendifferent staplers 600. According to the present invention, the torquelimit can be customized for each of staplers 600. As a result, memory808 can store the particular torque limit associated with thatparticular stapler 600. Furthermore, the torque limit can vary within anindividual stapler 600 according to cartridge 614. Therefore,adjustments for type of cartridge 614 can also be stored in memory 808.In some embodiments, adjustments for type of cartridge 614 may not varybetween staplers 600 and therefore a set cartridge variation can beprovided by system 800 or stored in data storage 716 of each cartridge614. During manufacturing, each stapler 600 is assembled and thenoperated to “wear-in” the clamping behavior.

In accordance with the present invention, a specific torque limit isdetermined for each stapler 600 and stored in memory 808 of chassis 608.FIG. 9A illustrates a procedure for initializing the torque limit for aparticular stapler 600. In step 902, stapler 902 is assembled. Afterassembly, in step 904, stapler 600 is “worn-in” by repeatedly performinga clamping procedure. Stapler 600 is worn in when the torque required toclamp is relatively stable (i.e., does not change significantly betweenactivations). In step 906, a series of shims of differing heights isutilized to enforce a known deflection of the tips of jaw 612 and anvil610 during clamping. A data set of clamping torque as a function of tipdeflection is then obtained.

FIG. 9B illustrates deflecting the tips by a known amount with shim 914.As is shown in FIG. 9B, shim 914 enforces a particular tip separationwhile jaw 612 and anvil 610 are clamped. In step 906, a series of testswith different shims 914 are accomplished to produce the data set asshown in FIG. 9C. As shown in FIG. 9C, the X-axis represents the tipdeflection enforced by each individual shim 914. The Y axis is therecorded torque data from a motor 918 in motor assembly 916 that driveschassis 608 of stapler 602 during the test to achieve a clampingcondition. In some embodiments, a relationship between the feedbackcurrent of motor 918 and the torque applied by motor 918 and theresulting force between jaw 912 and anvil 610 is known based onpreviously acquired calibration data utilizing motor 918 and numerousinstruments.

In step 908, the data can be fit to a function. In the example shown inFIG. 9C, the data is fit to a linear function Y=mx+b. A linear,least-squares method can be utilized to estimate the slope m and theoffset b. In this linear equation, Y is the torque required and X is thetip deflection. As shown in FIG. 9C, torque is provided inmilliNewton-meter (mNm) and deflection is provided in millimeters (mm).In the particular example provided in FIG. 9C, the slope m is determinedto be 21.5 mNm/mm and the offset b is 50 mNm. As discussed above, thevalues for m and b vary due to manufacturing variance between differentstaplers.

In step 910 the maximum torque value is determined for stapler 600. Insome embodiments, the maximum torque is determined by limiting themaximum tip deflection to 0.70 mm. The 0.70 mm is the tip separationthat is appropriate for a blue cartridge 614, which can be considered toestablish a safe baseline for a blue cartridge. This example valueprevents improper formation of the staple during firing due to tipseparation. As can be seen from FIG. 9C, or calculated by the abovelinear relationship, the particular stapler 600 illustrated in FIG. 9Chas a maximum torque value of 65 mNm. Torque values above this may allowtoo much tip deflection (and therefore too large a tissue gap) forproper staple formation. By enforcing a torque limit, enough torque issupplied to the clamp, but too much torque is not allowed, whichprevents larger tip deflections that result in improper stapleformation.

In step 912, the maximum torque value for stapler 600 is stored inmemory 808 of chassis 608 of stapler 600. The maximum torque value canthen be read from memory 808 during operation of system 10, asillustrated in FIG. 8, and utilized to control the maximum torquesupplied by motor 804 to end effector 602 during a stapling procedure.

In some embodiments, the calibrated maximum torque value, which can bedesignated as Tial is used as a baseline torque limit value for stapler600. From this baseline, during operation, the actual torque can beadjusted for particular cartridges 614. The adjustment can be based on alarge body of previously collected experimental and analytical dataacquired utilizing multiple cartridges and multiple staplers that areloaded into system 800. As an example, adjustments for variouscartridges 614 can be White=−3 mNm; Blue=+2 mNm; and Green=+9 mNm. Thesevalues are added to the maximum torque value and the adjusted valueutilized to control the torque output of motor 804 of motor assembly702. For example, if cartridge 614 was a blue cartridge, then themaximum torque value utilized during clamping is adjusted to 94 mNm.

The actual numbers utilized in the above description are forillustration only and should not be considering limiting. Each ofstapler 600 may have a different maximum torque value. Additionally, insome embodiments different safe tip deflections or other parameters canbe utilized. Further, adjustments for cartridge types may vary. Also,although the above discussion focused on a stapler instrument, similarcalibrations can be performed on other instruments, for example vesselsealers.

Other parameters can also be set during calibration. For example, thecalibrated torque limit can be set at a particular reference temperatureT_(ref). Other parameters may include wear coefficients, instrument lifecoefficients, and other parameters that relate to the particular stapler600.

Adjusting and calibrating the maximum torque limit for each instrumentallows more precise control of tip deflection during clamping. This canmaximize instrument performance. By calibrating each instrument, asmaller margin can be utilized than if a single constant parameter wasused uniformly across all instruments. Additionally, the uncertainty inthe tip deflection during clamping can be reduced by more preciselycontrolling clamping. Further, manufacturing yields can be increased byreducing dependence on manufacturing tolerances and adjusting formanufacturing variations.

Initialization of Motors in the Motor Assembly

In addition to calibrating and initializing stapler 600, motor assembly702 can also be calibrated and initialized to adjust for manufacturingvariations. Manufacturing variances in clamping motor 804 and firingmotor 802 as well as in mechanical converter 714 lead to variationsbetween motor assemblies. During motor assembly calibration, motor speedvs no-load current relationships I_(NL) and the torque constant K_(T)for each of clamping motor 804 and firing motor 802 are determined.

FIG. 10A illustrates a calibration method 1000 that can be utilized tocalibrate each of motors 804 and 802 of motor assembly 702. As shown inmethod 1000, step 1002 is to acquire an assembled motor assembly 702. Instep 1004, an initial calibration is performed. An example of acalibration procedure is illustrated in FIG. 10B. In step 1006, motors802 and 804 of motor assembly 702 are worn in. During the wear-inprocess, each of motors 802 and 804 are driven many cycles against aconstant torque in order to break in the geartrain of mechanicalconverter 714 and ensure that the grease is evenly distributed. In step1008, a final calibration is performed. The final calibration of step1008 and the initial calibration of step 1004 can be the samecalibration method, an example of which is shown in FIG. 10B. In step1010, the calibrated parameters are stored in memory 812 of motorassembly 702.

FIG. 10B illustrates an example of a calibration procedure 1012 that canbe utilized in steps 1004 and 1008 of FIG. 10A. As shown in FIG. 10B,step 1014 is to acquire no-load data for the motor, which could beeither clamping motor 804 or firing motor 802. To determine therelationship between motor speed and no-load current for a motor, themotor is driven at various speeds, one at a time in the forwarddirection first then in the backward direction. No-load current drawdata is measured, as well as the temperature of motor assembly 702 whileachieving each of the various speeds. In some cases, the no load currentdraw can be adjusted for temperature. As an example, the speedprogression in 10⁴ rotations per minute (rpm) may be [2.5, 1.5, 2.25,0.5, 2.0, 0.75, 1.0, 1.75, 0.25, 1.25, and 0.125]. However, other datataking progressions can be utilized. FIG. 10C illustrates data for aclamp motor 804 current as a function of motor speed in the forward(fwd) and backward (bak) directions.

In step 1016 the data is fit to a function, for example an exponentialfunction or a linear function, to determine a relationship between motorcurrent and motor speed. For example, a linear function withnon-polynomial terms that can be used to fit the data can be given by:

y=c1+c2*e ^(−x*x) ^(scale) +c3*x*e ^(−x*x) ^(scale)

where c1, c2, c3 are coefficients and x_scale is a constant.

In FIG. 10C, the solid curves represent a curve fit to the data. Thedata may be adjusted for temperature and filtered prior to fitting. Insome embodiments, the raw data can be adjusted as a function oftemperature based on previous modeling of motors as a function oftemperature. Additionally, the raw data can be filtered as a function oftime to reduce noise and provide averaging.

In some embodiments, a linear piecewise approximation can be optimizedto fit the function in order to ease further computation. A linearpiecewise approximation to the curve fit functions shown in FIG. 10C isillustrated in FIG. 10D. The linear piecewise approximation caneventually be stored in memory 812 as I_(NL).

Once the no-load current calibration is completed, procedure 1012proceeds to determination of a torque constant K_(T) (the torque outputper current input). As shown in FIG. 10B, step 1018 includes acquiringtorque loading data. In acquiring the torque loading data, the motorbeing calibrated (clamping motor 804 or firing motor 802) is drivenfirst against no load and then the load is ramped up to a known torqueloading and then ramped back down to no-load. The known torque loadingcan be provided by an external source such as a brake or dynamometer,for example. Data (i.e. torque output vs. current load) is gathered inboth the forward and backward directions for the motor being calibrated.Multiple sets of data can be taken for each of clamping motor 804 andfiring motor 802.

In step 1020, the torque data is analyzed to determine the torqueconstant K_(T). The data can be filtered and the torque constant K_(T)determined by comparing the change in torque (no load to known torqueloading) to the change in current (current at no load to the current atthe torque loading). Calculations for the multiple sets of data takenduring step 1018 can be averaged to determine the final calibrationtorque constant value.

FIG. 10E illustrates an example of motor speed and torque versus timefor a motor during data acquisition step 1018 according to someembodiments of the present invention. FIG. 10F illustrates motor speed,current, and cardan position as a function of time corresponding to thedata shown in FIG. 10E. As shown in FIG. 10F, the current data can befiltered to obtain a continuous function of current versus time for thetest.

As illustrated in FIG. 10A, in step 1010 after the final calibrationstep 1008 both the no-load current calibration data I_(NL) and thetorque loading calibration data K_(T) can be stored in memory 812 ofmotor assembly 702 and can be utilized during further calculations oftorque limits for motor assembly 702 as discussed further below.

Torque Limit Compensation

Referring back to FIG. 8, stapler 600 is only allowed to fire whenstapler 600 reaches a full clamp condition. The amount of torqueprovided by motor 804 to reach a complete clamp condition is limited bysoftware. This torque limit is generally set as a current limit, whichis a limit on the current that motor 804 is allowed to draw during theclamping process. The current limit is a function of the calibrationdata for the stapler 600, as discussed above. In other words, initiallythe torque limit is set at τ_(cal) as indicated above, adjustedaccording to the color of cartridge 614.

However, with repeated use of stapler 600, the effective torque limitcan drift and deviate from the original calibration data. In otherwords, the same torque that it takes to clamp stapler 600 after severaluses is different from, and typically less than, the torque that it tookto clamp stapler 600 at its initial calibration state. If the torquelimit were left unchanged, stapler 600 might be allowed to reach acomplete clamp actuation on challenge materials that it was not intendedfor, causing unintentional increased deflection of the tips between jaws612 and anvil 610. The increased tip deflection, as discussed above,provides for an inadequate tissue gap and improperly formed staples ifthe stapler were fired.

In accordance with some embodiments of the present invention, the torquelimit utilized for stapler 600 is adjusted according to multipleoperating parameters. The multiple operating parameters can, forexample, include the temperature of motor assembly 702, the articulationangle of wrist 604, the lifetime use of motor assembly 702 (e.g. thenumber of stapler firings affected by motor assembly 702), and thelifetime use of stapler 600 (e.g. the number of stapler firings usingstapler 600). The actual torque limit can be adjusted during operationin order to adjust for the age and operating condition of stapler 600.

FIG. 11 illustrates an algorithm 1100 for performing such an operation.

Algorithm 1100 can be performed by system 800 or system 800 incombination with processor 810 in motor assembly 702. As shown in step1002, algorithm 1100 is started when a command is received to clamp,prior to firing, stapler 600 in step 1102.

In step 1104, the parameters that are specific to stapler 600, which arestored in memory 808 of chassis 608, the parameters that are specific tomotor assembly 702, which are stored in memory 812 of motor assembly702, and the parameters that are specific to cartridge 614, which arestored in data storage 716, are retrieved. In step 1106, the adjustedmaximum torque limit is determined. The adjusted maximum torque limitcan be determined based on a number of parameters and a model that fitsthe wear characteristics of motor assembly 702 and stapler 600 incombination with a particular cartridge 614. As discussed above, some ofthe factors that can be including in the model include the temperatureof motor assembly 702 (T), the lifetime of motor assembly 702 measuredby the number of stapler firings (L_(MP)), the lifetime of stapler 600measured by the number of stapler firings (L_(inst)), and the angle ofwrist 604 (θ). In general, a set of parameters {Parameters} can bedefined that affect the torque limit utilized. In some embodiments, theset can be defined as {T, L_(MP), L_(Inst), θ, . . . } Other parametersmay also be utilized in the model.

Therefore, the adjusted maximum torque limit can be given by

τ_(com) =F({Parameters})

where the function F defines the model that best fits the behavior ofclamp 600 and motor assembly 702 over their lifetimes. The function Fcan be determined empirically over a large set of staplers 600 and motorassemblies 702 to accurately represent the wear characteristics overtime. In some cases, factors related to the various parameters may bescalars in the model while in other cases a better model has certainfactors being additive while other factors are scalars. For example, amodel for calculating the maximum torque limit may be given by

τ_(com) =F({Parameters})=ƒ(T)*g(L _(MP))*h(L _(inst))*y(θ)+z(T)+k(L_(MP))+x(L _(inst))+p(θ)+C,

where f, g, h, y, z, k, x, and p represent particular functions of theindicated parameters and C represents a general offset term. As shown inthe above equation, the corrections can include scalar components andadditive components for each of the parameters in the parameter set. Insome models, certain of functions f, g, h, and y can be set to one (1)if that parameter is not a scalar component while functions z, k, x, andp are set to 0 if the corresponding parameter is not an additivecomponent. The above example of F{Parameters} is not limiting and otherfunctions can be utilized in the modeling. Some particular examplemodels are presented in further detail below.

In step 1108, the motor current limit is determined from the torquelimit. As an approximation, there is a linear relationship between thecurrent and the desired torque for motor 804. Therefore, conversion fromtorque limit to current limit involves scaling the torque limitaccording to the linear relationship to determine the current limit formotor 804 in the clamping process.

In step 1110, stapler 600 is clamped utilizing the adjusted motorcurrent limit described above. As discussed above, stapler 600 isclamped when motor 804 achieves a particular position while notexceeding the adjusted motor current limit. Once stapler 600 is in aclamped condition, then stapler 600 can be fired. In step 1112, after asuccessful clamping is achieved, algorithm 1100 waits for a user inputor confirmation prior to firing. In step 1114, stapler 600 is fired.

As shown in FIG. 11, in some embodiments firing step 1114 can includedetermining the firing torque limit 1120, determining the firing motorcurrent limit 1122, and firing using the firing motor current limit1124. Excessive torque applied to a fire cardan joint in stapler 600 canpose a problem to breaking the fire cardan joint or breaking theleadscrew in cartridge 614. Excessive torque could also cause knife 616in cartridge 614 to be jammed against a hard stop with too much force,possibly breaking a piece of knife 616 into the patient. Both the drivetrain and cartridge leadscrew and knife mechanisms should include anadequate safety margin to prevent breakage during operation. The firingtorque limit (the torque limit of firing motor 802) can be adjusted toprevent the torque being applied to the mechanism to approach a levelthat damages stapler cartridge 614 or cartridge drivetrain components.

Determining the firing torque limit for firing motor 802 in step 1120can be similar to determining the torque limit for clamping motor 804 asdiscussed above with respect to step 1106. As discussed above, thefiring torque limit for firing motor 802 can be adjusted using afunction of, for example, temperature, motor assembly life, instrumentlife, and other parameters. The same forms of the adjustment equations,in some cases with different coefficients, can be used in adjusting thetorque limit for firing motor 802 as those discussed above can be usedfor adjusting the torque limit for clamping motor 804. Further, the sameform of equation for determining the motor current limit as discussedabove with step 1108 can be utilized in step 1122. Firing step 1124 iscomplete when firing motor 802 reaches a particular position while notexceeding the firing motor current limit.

In step 1116, parameters are adjusted to reflect the firing. For examplethe parameters L_(MP) and L_(inst) can both be incremented. In step1118, the adjusted parameters can be stored for future use. For example,L_(MP) is stored in memory 812 and L_(inst) is stored in memory 808 foruse in the next stapling procedure involving motor assembly 702 orstapler 600.

As discussed above, the torque limit can be translated to a currentlimit for motor 804 in step 1108. In some cases, the relationshipbetween the current limit and the torque limit can be given by:

I _(limit) =I _(NL)+τ_(com) /K _(T),

where I_(limit) is the current limit provided to motor 804, I_(NL) isthe no-load current for motor 804 at the time of calibration, K_(T) is atorque constant characteristic of the motor assembly drive train, andτ_(com), as discussed above, represents a modeled and compensated torquelimit provided to minimize error in clamping. I_(NL) represents thefriction compensation for the motor assembly and can be a function ofspeed. The parameter K_(T) is related to the conversion of torque tocurrent in motor 804. Initial K_(T) at a reference temperature T_(ref)may be determined during a calibration of motor assembly 702 asdiscussed above. In some models, K_(T) can be given by

K _(T) =K _(Tcal)*[1−η*(T−T _(ref))],

where K_(Tcal) is the calibrated conversion coefficient and q is atemperature coefficient related to the operation of motor 804. In somemodels, the value for I_(NL) can be given by:

I _(NL) =I _(cal)*[1−μ*(T−T _(f))]*[1−κ*(L _(MP))],

where I_(cal) is the calibrated no-load current draw representing theloss in the motor assembly 702 as a function of speed, μ is thetemperature coefficient, T is the temperature of motor assembly 702(measured by electronics 810), T_(ref) is a reference temperature, κ isthe motor assembly life coefficient, and L_(MP) is the number of timesthat motor assembly 702 has fired a stapler. The reference temperatureT_(ref) can, for example, be the temperature at which motor assembly 702is calibrated and can be stored in memory 812. As can be seen from theabove equations in this model, the calibrated current limit for stapler600 at T=T_(ref) is given by I_(limit)=I_(cal)+τ_(cal)/K_(Tcal), whichcan be used in the initial calibration phase to determine both I_(cal)and K_(Tcal). The values of I_(cal) and K_(Tcal) can, in someembodiments, be stored in memory 812.

In some models, the adjusted torque limit can be given by

τ_(com)=τ_(des) *W(θ)*[1−α*(T−T _(ref))]*[1−β*(L _(MP))]*[1−γ*(L_(ins))]+δ*(T−T _(ref))+∈

where α is a temperature coefficient, β is the life coefficient of motorassembly 702, γ is the life coefficient of stapler 600, δ is theconstant offset temperature coefficient and ε is a constant offset. Thevalue of τ_(des) can be given by the sum of τ_(cal) and cartridgeadjustment, as discussed above.

The function W reflects the added friction when wrist 604 isarticulated. In some embodiments, the function W is a cosine function ofthe angle θ through which wrist 604 is articulated. As such, in someembodiments W can be given by

${W(\theta)} = \frac{1}{1 - {\xi \left( {1 - {\cos (\theta)}} \right)}}$

where θ is the wrist angle of wrist 604 as shown in FIG. 8 and is theparameter that determines the influence of the wrist angle on the torquelimit. As illustrated, at θ=0 degrees, W(θ) will be 1. As the angleincreases, however, the friction at wrist 604 increases, resulting in amultiplicative increase in τ_(com) by W(θ). In some embodiments, thefunction W(θ) can be implemented as a look-up table. The torque limitwrist adjustment W(θ) can be utilized for any surgical instrument with awrist and the need to transmit a force through the wrist.

The various scalar coefficients shown above can be adjusted to bestmodel the lifetime behavior of motor assembly 702 and of stapler 600.These coefficients include the temperature coefficients η, μ, α, and δ;the lifetime coefficients κ, β and γ; additive coefficient ε; and wristcoefficient ξ and can be determined through repeated testing of variousones of stapler 600 and motor assembly 702 through their lifetimes or insome cases can be customized through calibrations done on individualmotor assemblies or instruments. In some embodiments, if thecoefficients are determined by averaging over a large number of motorassemblies and staplers and do not vary between individual motorassemblies or staplers, then they can be stored in system 800 where themodeling is calculated. Otherwise, the coefficients can be stored withtheir individual components. For example, the temperature coefficientsη, μ, α, and δ; the lifetime coefficients κ and β can be stored inmemory 812 while the lifetime coefficient γ can be stored in memory 808.

As indicated above, for example δ can be set to 0 if temperature is ascalar component not an additive component and a can be set to 0 iftemperature is an additive component and not a scalar component. In thismodel, with α and δ both non zero temperature is both a scalar andadditive factor. In some embodiments, the coefficients can be within thefollowing ranges: 0≤α≤1; 0≤β≤1; 0≤δ≤1; −10≤ε≤10; 0≤γ≤1; 0≤μ≤1; 0≤κ≤1;0≤η≤1; and 0≤ξ≤1. In many cases, the coefficients are less than about10⁻².

The primarily scalar model example provided above is not the only modelthat can be utilized to adjust the torque limits for operation ofstapler 600 for lifetime drift as a function of temperature. Othermodels may utilize, for example, a primarily additive model orcombinations of additive and scalar components can be added, ornonlinear models could be used. Models can be expanded as needed toinclude combinations of multiplicative and additive factors in order tobest model the behavior of stapler 600 during its lifetime of use.

As suggested above, there is a variety of models that can be utilized tomodel the adjustment to the torque limits. As suggested above, dependingon the system, certain variables may be modeled as an additive effectand others may be modeled as a multiplicative effect. In someembodiments, the model can be tailored for the lifetime of a particularstapler system. This can be accomplished by setting some of theparameters to zero and some to non-zero values. In some embodiments, themodeling equation for τ_(com) can be expanded to include more additivefactors and further combinations of additive and multiplicative factorsin the modeling.

The current limit utilized to control clamp motor 804, I_(limit), can beprovided to electronics 810 in order to control motor 804. The modelutilized to provide the adjusted current limit operates to provideproper clamping throughout the operable lifetimes of stapler 600 and ofmotor assembly 702. The torque compensation algorithm described aboveallows the surgical system utilizing stapler 600 to effectively andsafely clamp on appropriate materials (and thicknesses) whilemaintaining appropriate tissue gap and may prevent a full clamp onmaterials (and thicknesses) that would cause inadequate tissue gap. Thisoperation helps to prevent excessive tip deflection and also preventsfiring and causing improperly formed staples and surgical interventionthat would result from improperly formed staples.

Homing Adjustments

In some embodiments of the invention, a homing procedure can be providedto further adjust the torque limits. The homing procedure is implementedwhen stapler 600 and motor assembly 702 is first attached to patientside cart 22. In some embodiments, system 800 can drive stapler 600through a preset range of motions and tests while monitoring thecorresponding performance of stapler 600 and motor assembly 702.Current, position, and torque of motors 804 and 802 can be monitored byelectronics 810 and communicated to processor 800. Processor 800 canadjust coefficients and parameters to correct for the measured behaviorof stapler 600 and motor assembly 702 during homing. Those correctedcoefficients and parameters can be utilized while operating stapler 600with motor assembly 702 as described above.

Individual parameters can be adjusted according to the performancetests. As such, the calibration data, for example τ_(cal), can beadjusted as a result of the homing process in addition to the factorsdescribed above prior to utilization of stapler 600.

The above detailed description is provided to illustrate specificembodiments of the present invention and is not intended to be limiting.Numerous variations and modifications within the scope of the presentinvention are possible. The present invention is set forth in thefollowing claims.

What is claimed is:
 1. A method comprising: operating a motor assembly,the motor assembly including a motor, a memory to store calibratedparameters of the motor, and electronics coupled to the memory and themotor, the electronics being configured to: retrieve the calibratedparameters from the memory; provide the calibrated parameters to anexternal system; and receive control signals for driving the motor fromthe external system, the control signals being based on the calibratedparameters; wherein the calibrated parameters comprise a motor speedversus no-load current relationship for the motor determined by aprocedure comprising: performing an initial calibration of the motor;wearing in the motor after performing the initial calibration;performing a final calibration of the motor after wearing in the motor;and storing the calibrated parameters in the memory based on the initialcalibration and the final calibration.
 2. The method of claim 1, whereinthe calibrated parameters further comprise a torque constant.
 3. Themethod of claim 2, wherein performing the final calibration comprises:acquiring torque loading data for the motor; and determining the torqueconstant from the torque loading data.
 4. The method of claim 1, whereinthe motor speed versus no-load current relationship is a function ofmotor speed and direction.
 5. The method of claim 1, wherein performingthe final calibration comprises: acquiring no-load data for the motor;fitting a function to the no-load data to determine the motor speedversus no-load current relationship.
 6. The method of claim 5, furthercomprising fitting a linear piecewise function to approximate thefunction.
 7. The method of claim 1, further comprising storing lifetimedata in the memory of the motor assembly.
 8. The method of claim 7,wherein the lifetime data includes a motor assembly lifetime.
 9. Themethod of claim 1, wherein the motor is a clamping motor.
 10. The methodof claim 1, wherein the motor is a firing motor.
 11. A motor assembly,comprising: a motor; a memory to store calibrated parameters of themotor; and electronics coupled to the memory and the motor, theelectronics being configured to: retrieve the calibrated parameters fromthe memory; provide the calibrated parameters to an external system; andreceive control signals for driving the motor from the external system,the control signals being based on the calibrated parameters; whereinthe calibrated parameters comprise a motor speed versus no-load currentrelationship for the motor determined by a procedure comprising:performing an initial calibration of the motor; wearing in the motorafter performing the initial calibration; performing a final calibrationof the motor after wearing in the motor; and storing the calibratedparameters in the memory based on the initial calibration and the finalcalibration.
 12. The motor assembly of claim 11, wherein the calibratedparameters further comprise a torque constant.
 13. The motor assembly ofclaim 12, wherein the performing the final calibration comprises:acquiring torque loading data for the motor; and determining the torqueconstant from the torque loading data.
 14. The motor assembly of claim11, wherein the performing the final calibration further comprises:acquiring no-load data for the motor; and fitting a function to theno-load data to determine the motor speed versus no-load currentrelationship.
 15. The motor assembly of claim 14, wherein fitting thefunction comprises fitting a linear piecewise function to approximatethe function.
 16. The motor assembly of claim 12, wherein the motorspeed versus no-load current relationship is a function of motor speedand direction.
 17. The motor assembly of claim 11, wherein the memoryalso stores lifetime data.
 18. The motor assembly of claim 17, whereinthe lifetime data includes a motor assembly lifetime.
 19. The motorassembly of claim 15, wherein the motor is a clamping motor.
 20. Themotor assembly of claim 15, wherein the motor is a firing motor.